Archana Choudhary, 23rd January 2009, Power System NM

Automation of Lift Irrigation Schemes Network Management

ABB Group May 22, 2012 | Slide 1

Overview of Todays Presentation

Water Automation projects with ABB India Lift Irrigation projects under execution Overview of SCADA system in Lift Irrigation projects Product overview Operation & Maintenance

ABB Group May 22, 2012 | Slide 2

Your Partner in turnkey solution for:

Motor Motor Pump Pump

Irrigation Substation & pumping station automation. Water Transport and Supply Water / Wastewater Treatment Seawater Desalination

Motor

Pump

Motor Motor Pump Pump Motor Pump Motor Pump Motor Pump Motor Pump Motor Pump

Motor

Pump

Motor

Pump

Motor Pump Motor Pump Motor Pump Motor Pump

ABB Group May 22, 2012 | Slide 3

One stop shop solutions from ABB

Energy supply Energy distribution

Motors and Drives Instrumentation

SCADA and Automation Actuators

ABB Group May 22, 2012 | Slide 4

Networks and controls

Network Management System

ABB Group May 22, 2012 | Slide 5

SCADA Defined

What is SCADA ?

SCADA stands for Supervisory Control and Data Acquisition SCADA is a type of application Not an off- the-shelf product or technology Used in a wide range of industrial processes Provide monitoring and control of remote equipment and facilities Primary functions of SCADA system:

Data acquisition Data communication Data presentation Control

ABB Group May 22, 2012 | Slide 6

Various protocols supported by SCADA

IEC 61850 Master Protocol for relay communicatios LONWORKS Devices DNP V3.00 Master Protocol DNP V3.00 Slave Protocol IEC 60870-5-101 Master/Slave Protocol IEC 60870-5-103 Master Protocol IEC 60870-5-104 Master/slave Protocol Modbus Master/slave Protocol OPC DA client for PLC communication

ABB Group May 22, 2012 | Slide 7

SCADA Features

Data Acquisition Redundant Data Processing Calculations Supervisory Control Tagging Flexible Operator Authority Map board / Video Wall Alarm Handling & Presentation Historical and Planning data handling One-line and Tabular Presentation Trend Presentation Load Shed and Restore On-line Context Sensitive Help Disturbance Data handling Control System Supervision Full graphic HMI Network Topology Hot / standby redundant support Colour Setting tools Zooming, panning and de-cluttering Data storage into open databases like Ms-SQL server, Oracle etc.,

ABB Group May 22, 2012 | Slide 8

SCADA User Benefits

User Benefits

Always up-to-date and reliable information about network state Secure operation of the network Manual dressing of network operational state Sorting of essential information at disturbances Easy to define calculations and reports

ABB Group May 22, 2012 | Slide 9

Graphical User Interface

Operator Station based on Microsoft Component Features

On-line Configurable Menus and Toolbars Microsoft Excel for Report presentation Trend and instantaneous curves based on ActiveX components Support for large screen display walls Support for Remote Workstations on many medias WEB based system Intuitive usage less risk for operational errors Reduced operator training costs Advanced integration possibilities with minimal costs Future proof - easy adaptation to new requirements

User Benefits

ABB Group May 22, 2012 | Slide 10

SCADA Architecture for Master Control Center

GPS Antenna Workstation -1 Workstation -2 Workstation -3 Engineering W/S

HOPF

LAN A (Main) LAN B (Hot SB)

Ethernet Switch Router

Ethernet Switch

A4 B/W Laser Printer

A4 Colour Printer

To Backup Control Centre

Main and Redundant SCADA/DMS Server Redundant FEP For RTUs & FRTUs Main and Redundant HIS(UDW) Server

Router/Firewall

Fiber Optic Network

For GIS services

Substation RTUs Pumping station PLCs

ABB Group May 22, 2012 | Slide 11

(220KV/132KV/66/11 KV)

Water Automation projects with ABB India

ABB Group May 22, 2012 | Slide 12

Water Projects with ABB India

Kerala Water Distribution System. HNSS Lift Irrigation Project. Indra Sagar Lift Irrigation Project. PADA Lift Irrigation Project. Sripada Sagar Lift Irrigation Project . Rajiv Sagar Lift irrigation Project . Dhummagudem Lift Irrigation Project Pkg-1 & Pkg-4. Bhima Lift Irrigation Project . Kalwakurty Lift Irrigation Project. Pranahita Chevalla LIS Pkg-5, Pkg-7 and Pkg-12 Thotapalli Lift Irrigation Project.

ABB Group May 22, 2012 | Slide 13

Lift Irrigation Projects Under Execution

HNSS Lift Irrigation Project 12 pumping stations.

Indra Sagar Lift Irrigation Project 3 pumping stations PADA Lift Irrigation Project Bhima Lift Irrigation Project Kalwakurty Lift Irrigation Project Kerala Water Distribution System. 5 pumping stations 2 pumping stations 1 pumping station

ABB Group May 22, 2012 | Slide 14

Overview of SCADA system in Lift Irrigation projects

ABB Group May 22, 2012 | Slide 15

SCADA In Lift Irrigation Schemes

Functionalities Requirements

Remote operation and management Operation on Unmanned location Data collection, storage, retrieval and archive Alarm and events management Reports generating Process monitoring and control

ABB Group May 22, 2012 | Slide 16

Lift Irrigation Scheme Requirement

The details of four levels of automation such as

Local equipment panel (Level 1) Local PLC control (Level 2) Regional Control through network and Local PC (Level 3) Central Control through PCs and network of entire system (Level 4) Benefits in terms of

Extent of control Performance Reliability Reduction in manpower, etc

ABB Group May 22, 2012 | Slide 17

Automation in Pumping Station

Programmable Logic Controller Field Instrumentation :

Pressure Measuring Instruments Flow Measuring Instruments Level Measuring Instruments Temperature Measuring Instruments Vibration Monitoring System

SCADA Equipments Communication Equipments

ABB Group May 22, 2012 | Slide 18

Components of SCADA System

Larger computers( Servers & workstations) running various software Provide Human-machine Interface( HMI) for operators Accept, process and store data from RTU ( substation automation) and PLC ( pumping system automation). Regulate the controlled system Distribute data to other systems

ABB Group May 22, 2012 | Slide 19

Components of SCADA System

Communication Network

Connect Central Control Station and RTU/RPU/PLC Types of Networks

Direct connection (Fiber Optic Backbone) Telephone (leased or dial-up line) Radio Satellite (GPRS/CDMA) VSAT

ABB Group May 22, 2012 | Slide 20

Technology Innovation and Future Trends

Integration of SCADA with corporate IT system Integration of SCADA with GIS Integration of advanced process control technologies Standardization More open system and interoperability Wider use of wireless network

ABB Group May 22, 2012 | Slide 21

Application Example

Remote Access and Control

Provide continued operational control of the facilities in the event of a facility evacuation from any other facility. Provide support staff with remote access to process control system for troubleshooting and maintenance. Provide view-only access to process monitoring system for external end-users.

ABB Group May 22, 2012 | Slide 22

Overview Of HNSS Pumping Stations & Master Control Centre

SCADA Workstation Operator Workstation Main Server Standby Server Operating Workstations SCADA Workstation Operator Workstation

Ethernet Switch Ethernet Switch Ethernet Switch

Radio Equipment PLC Controller

Radio Equipment PLC Controller PLC Controller

Radio Equipment

PS-1
Operator Workstation

PS-12
SCADA Workstation Operator Workstation

SCADA Workstation

PS-4 (Main Control Center)

Ethernet Switch

Ethernet Switch

Radio Equipment PLC Controller

Radio Equipment PLC Controller

PS-2
SCADA Workstation Operator Workstation SCADA Workstation Operation Workstation SCAD Workstation Operator Workstation SCADA Workstation Operator Workstation SCADA Workstation Operator Workstation

PS-11
SCADA Workstation Operator Workstation

Ethernet Switch

Ethernet Switch

Ethernet Switch

Ethernet Switch

Ethernet Switch

Radio Equipment PLC Controller

Radio Equipment PLC Controller PLC Controller

Radio Equipment PLC Controllerv

Radio Equipment PLC Controller

Radio Equipment PLC Controller

Radio Equipment

PS-5

PS-6
Radio Link

PS-7

PS-8

PS-9

PS-10

ABB Group May 22, 2012 | Slide 23

Note:-

SCADA Architecture for Pump House in Kalwakurity LIS

Main Server Standby Server
Workstation -1 Workstation -2 Workstation -3 Workstation -4 Workstation -5

Ethernet Switch-1

Ethernet Switch2 PLC Controller

PRINT SERVER

Dot Matrix printer Dot Matrix printer Laser Jet printer

DI, DO, AI & AO

Unit Control Board, Synchronizing Equipment

Hardwires signals from field instruments

DI, DO, AI & AO

Field Instruments

11KV Switchyard
ABB Group May 22, 2012 | Slide 24

KWA : Reservoir Monitoring Through SCADA

ABB Group May 22, 2012 | Slide 25

KWA Process Layout

ABB Group May 22, 2012 | Slide 26

KWA : Overview of Control Center

ABB Group May 22, 2012 | Slide 27

Service
Trouble Shooting Service Contracts Experts, Consultancy Spares

Modernization, Extension

Remote service, Maintenance System

Training

ABB Group May 22, 2012 | Slide 28

Product Overview

ABB Group May 22, 2012 | Slide 29

Automation Hardware & Software

Hardware

Remote Terminal Unit RTU 560, RTU211. ( for substation automation) Programmable Logic Controller AC800, AC500, AC31 ( pumping station automation)

Software

SCADA Network Manager, Micro SCADA Pro, 800xa GIS Facilplus.

ABB Group May 22, 2012 | Slide 30

Market Requirements for Modern RTUs

Commands

NCC

Monitoring Direction

Process
+ serial interfacing of IEDs

Station HMI

Integrated HMI PLC functions Data archives

ABB Group May 22, 2012 | Slide 31

Maintenance

ABB Group May 22, 2012 | Slide 32

Maintenance Overview
Maintenance, which has been a non-core area for a pumping Stations, is an integral area, which has to be looked in for better performance. Maintenance of equipment is of primary importance for every plant. Maintenance procedures should be given a high priority in the daily work schedule, because making sure that the plant equipment functions properly is an important factor in achieving the proper water quality discharge. By proper Maintaining the Plant Equipment, an operator can extend its Plant Life by at least 25 %.

ABB Group May 22, 2012 | Slide 33

Maintenance in LIS
Proper Maintenance is required for all the systems in the Pumping Stations.

Electrical Systems Mechanical Equipments Automation Equipments Instrumentation

ABB Group May 22, 2012 | Slide 34

Maintenance Overview

Types of Maintenance:

Preventive Maintenance. Predictive Maintenance. Breakdown maintenance.

ABB Group May 22, 2012 | Slide 35

Preventive Maintenance

It should be considered as a part of your normal daily work routine and something that is necessary to keep the plant operation at full capacity. Preventive Maintenance is the form of Inspection and tests that are performed every day.

Types of Preventive Maintenance

Planned Maintenance:

Planned Maintenance is defined as the periodic scheduled removal of equipment from service for the disassembly and inspection of Internal working parts.

Routine Maintenance:

Routine maintenance is best described as the daily general Inspections and test including regular lubrication, that are performed as a part of regular operation of the Plant.

ABB Group May 22, 2012 | Slide 36

Predictive Maintenance
Predictive Maintenance is regular monitoring of the actual mechanical condition, operating efficiency, and other indicators of the operating Condition of process systems will provide the data required to ensure the maximum interval between repairs and minimize the number and cost of unscheduled outages created by failures.

ABB Group May 22, 2012 | Slide 37

Key points for Predictive Maintenance:

Based on the Criticality of the Process Value & Instruments Value the Checking and Calibration should be done.

Improper Functioning of Instruments. SCADA Value is not matching with the Field Values. Based on the Alarm Generated.

ABB Group May 22, 2012 | Slide 38

Breakdown Maintenance
During the Shut Down Operation Breakdown Maintenance should be done. Breakdowns in industrial manufacturing systems can have significant impact on the profitability of a business. Expensive production equipment is idled, labor is no longer optimized, and the ratio of fixed costs to product output is negatively affected. Rapid repair of down equipment is critical to business success; and this can be overcome by proper Preventive and Predictive maintenance.

ABB Group May 22, 2012 | Slide 39

Key Points for Breakdown Maintenance:

Before shutdown Collect the required data for preparing shutdown procedures. During Shut down Clean all the Instruments and Equipments by dismantling. Critical Instruments can be Calibrated during this Time.

ABB Group May 22, 2012 | Slide 40

Programmable Logic Circuits:

Protect the PLC from dust free environment by cleaning the room using blowers, etc.. Check for the Error Status Led and based on that fault can be identified. Check for proper functioning of UPS supply and battery connected to the PLC. Check whether the A/C temperature Check whether the cable is properly connected from the field devices in to the TB. Periodically back up of PLC configuration.

ABB Group May 22, 2012 | Slide 41

Cost Effective Maintenance

Self-diagnostics Hot swap maintenance On-line changes of application program and configuration Compact Flash memory for storage of application and data Search & Navigation

Comprehensive maintenance features reduce down-time

ABB Group May 22, 2012 | Slide 42

SCADA Equipments :

Protect the systems from dust free environment by cleaning the room using blowers, etc.. Check for the A/C temperature. Check whether the communication cable are properly protected and connected. Update with recent Antivirus developed. Periodically back up of SCADA configuration.

ABB Group May 22, 2012 | Slide 43

Steps to Deploy SCADA System

Analyze process requirements System design Hardware selection and procurement Control system programming HMI development Installation Testing Startup system

ABB Group May 22, 2012 | Slide 44

Communication Equipment :

Check whether all the communication cables are away from power cables. Regularly check whether all the connection points are fixed tightly.

ABB Group May 22, 2012 | Slide 45

Calibration:

Calibration is the process of establishing the relationship between a measuring device and the units of measure. This is done by comparing a device or the output of an instrument to a standard having known measurement characteristics.

Calibration can be called for:

with a new instrument when a specified time period is elapsed. For example PG,PS,PT etc when a specified usage (operating hours) has elapsed. when an instrument has had a shock or Vibration which potentially may have put it out of calibration whenever observations appear questionable

ABB Group May 22, 2012 | Slide 46

Instrumentation- Pressure Measuring Instruments

Maintenance for Pressure Measuring Instruments:

Proper calibration is required for every three Months. Routine maintenance should be done every day by checking any leakage is there in isolation valve, impulse & piping line, pointer alignment and process connections. Pressure Calibrating Instruments:

Dead Weight Tester Handheld Pressure Calibrator. Multi-calibrator for Transmitters

ABB Group May 22, 2012 | Slide 47

Instrumentation- Flow Measuring Instruments

Types:

Flow switch Electromagnetic Insertion type

Flow Switch :

Switch will be calibrated by applying certain pressure based on the flow and confirm whether NO & NC is getting changed. Calibration is required for a period of 6 Months. Calibration Equipment: Equipment which can generate Pressure.

ABB Group May 22, 2012 | Slide 48

Instrumentation- Flow Measuring Instruments

Electromagnetic Insertion Type:

Routine Maintenance should be done by checking the proper connection and proper parameter display in the SCADA System. Zero setting Calibration should be done for every 6 months by changing the mode in to zero setting by ensuring no flow in the pipe line and meter should show zero in display. Zero Setting should be done for a period of 3 Months. Normal Calibration is required whenever the instrument is not showing the proper zero value after zero setting.

Calibrating Equipment:

Laptop Calibration kit from manufacturer

ABB Group May 22, 2012 | Slide 49

Instrumentation Level Measuring Instruments

Types

Ultrasonic Level Transmitter Conductivity Type Level Switch: Ensure proper mounting of the Instrument. Ensure the Proper current output is coming during periodic checking based on the Level For e.g.: Tank Height : 7m; Transmitter Output : (4-20)mA For this the Transmitter should deliver 4 mA for 0% Level and 20 mA for 100% Level.

Ultrasonic Level Transmitter:

Calibration should be done by Configuration setting in the manual The device can be programmed with the help of a magnetic key board supplied with the Unit. Checking should be done for a period of 3 months. Calibration should be done when the parameters are not matching. Making sure the instrument is protected against overheating.

ABB Group May 22, 2012 | Slide 50

Instrumentation Level Measuring Instruments

Level Switch Type : Conductivity Type

Clean the probe during the time of checking. Checking should be done by dipping the Rod in to the water and check for the chances in NO/NC when the rod touches the water. Checking should be done once in 3 months. Standard Calibration is not required.

ABB Group May 22, 2012 | Slide 51

Instrumentation Temperature Measuring Instruments

Temperature Gauges Temperature Switch Temperature Scanners

Temperature Gauges :

Calibration is done by applying particular temperature from temperature bath and check for the changes occurred. Calibration should done once in three months. Temperature Generating Source Temperature bath

Calibration Equipment:

ABB Group May 22, 2012 | Slide 52

Instrumentation Temperature Measuring Instruments

Temperature Switch:

Calibration is done by applying particular set point temperature from temperature bath and check for the NO/NC changes occurred. Calibration should done once in three months. Temperature Generating Source Temperature bath Apply particular resistance or mV through decade resistance box or through Multi-calibrator and check for the changes occurred by comparing with the standard chart. Calibration should be done once in 6 months. Ensure proper covering and protection is done. Standard reference chart for RTD and Thermocouple Decade resistance Box or Multi-calibrator

Calibration Equipment:

Temperature Scanner:

Calibration Equipment:

ABB Group May 22, 2012 | Slide 53

Instrumentation Vibration Mointoring System

Check for the proper alignment of the sensor. Clean the sensors periodically without shaking the Sensors. Check for the Error Status Led and based on that fault can be identified. Vibration Parameters can be checked by comparing with the Handheld Vibration Meters. Calibration Equipment:

Handheld Vibration Meters.

ABB Group May 22, 2012 | Slide 54

Benefits Of Maintenance :

Optimum availability Optimum Operating Conditions Maximum utilization of maintenance resources Optimum equipment life Minimum Spares inventory Ability to react quickly

ABB Group May 22, 2012 | Slide 55

 ABB Group May 22, 2012 | Slide 56